moulds and components | Multi-component
Above: A key attraction of the Flexi-Cube system is its flexibility to place moulding stations at unequal indexing distances, opening up numerous layout options
and the finished handle is removed from the mould at the fifth station. All operations are carried out within active parts of the 15s cycle time as the mould is only open during indexing. According to Boucherie sales manager Freddy
Vandemaele, the customer specified a 24-cavity three-component mould to meet its projected annual volume requirements but was evaluating a variety of mould constructions, including designs using rotary indexing platens and traditional cube variants (he says the customer already has cube moulds in operation). Vandemaele says the rotary mould option was not
Right: Three component PP/TPE handle produced on a 15s cycle time on a five-sta- tion, 24-cavity Flexi-Cube mould
practical in this case as it would have required a huge moulding machine to accommodate a single-face 24-cavity mould large enough to produce the three- component
part.The Flexi-Cube mould was adopted over a traditional cube type for its compact size, ability to integrate the additional cooling stage, and its fast indexing time of just 0.7s. The system is currently in production on a
550 tonne Engel Duo machine equipped with three injection units (the second mounted in a piggy back position and the third integrated on the moving platen) and is manufacturing 120,000 parts every 24 hours. Vandemaele adds that the mould is unloaded by a six-axis robot and is integrated directly to an automated assembly line, which determines the overall output. The carrier system used in the Flexi-Cube
system lifts the moulded component clear of the female cavities each time it is indexed, which is not necessarily essential in production of a multi-component mould. “For realising a multicomponent
application, the goal is to bring the first component into the second station and further on. If the part design for the second component allows it to stick on the core then a turning table or cube mould can bring the part to the next station, and in this case it is
42 INJECTION WORLD | April 2013
not necessary to disengage the part,” says Vandemaele. “If the part design calls for the second component
all around the part then it has to be released and deposited on a new core. This can be done by robot transfer, index platen or also with the Flexi-Cube,” he says. However, while the part must be released from the
core to utilise the Flexi-Cube system, Vandemaele says that provided this is considered in the design then any component can be manufactured using the technique. He says the mould technology is also well suited to in-mould assembly processing. Boucherie sees one of the key advantages of its
mould concept being its flexibility. Versions for four or even more injection moulded components can be produced, either with or without intermediate cooling stations between moulding stages. Additional ejection stations can be provided where premade structures – such as brush bristles or inserts – can be introduced to the part. However, the company says the technique is equally suitable for simpler two-component applica- tions where it allows cavitation to be maximised. Integration with the moulding machine is also said to be more straightforward. There is no need for a rotary turntable or centre plate turning device and all the necessary servo motors and motion controls are integrated into the mould and connect to the moulding machine via a simple interface. Boucherie also uses its own, well-proven hydro-me- chanical valve gated hot runner. Vandemaele says the company is working on a number of new confidential projects exploit- ing the advantages of the Flexi-Cube technol- ogy. “Competitive means making a compari-
son between investment and results,” he says. “The benefits are multiple. For example, the number of parts per hour, the reduced machine investment, more compact space, reduced maintenance and cycle time, less cavities to reach the demanded output.” ❙
www.boucherie.be
www.injectionworld.com
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